Raster Image Processor With Printhead Profile Compensation for a Multi Level Digital Printing Machine

ABSTRACT

System and method of calibration, screening, and compensation for multiple gray-level digital presses. Unequal quantization of the input range is employed with compensated overlapping of sub-ranges. Multiple instances of bi-level screening algorithms, tone modification functions, and a recombination algorithm are employed to produce calibrated screening on individual tone ranges. The method works with any bi-level screening algorithm and devices with any number of gray-levels. Quality imaging results from high detail, high tonal accuracy, low screening noise, and lack of printed artifacts. Dynamic re-calibration is facilitated. The elimination of the constraint of evenly spaced gray-levels has advantages of cost and yield for print head fabricators and digital press manufacturers. Multiple implementations are given for hardware and software embodiments. The present invention, which comprises a print profile for each colorant, is extended to comprise additional print profiles, as needed, specifying the print characteristic of a single or group of aberrant nozzles.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and is a continuation-in-part ofU.S. Utility patent application Ser. No. 14/534,587 filed on Nov. 6,2014, now pending, that claims priority to U.S. Provisional ApplicationSer. No. 62/067,790 filed on Oct. 23, 2014, now pending, U.S.Provisional Application Ser. No. 61/993,976 filed on May 15, 2014, nowpending, and U.S. Provisional Application Ser. No. 61/932,848 filed onJan. 29, 2014, now expired, all of which are hereby incorporated intothis specification by reference in their entirety.

BACKGROUND OF THE INVENTION

FIG. 1 shows a conventional bi-level digital printing system 100 havinga bi-level digital printing machine 102 and a raster image processor 104widely used by commercial print shops to print high volume and highquality prints from an input file 80 such as a raster file format (tiff,JPEG, etc.) or a vector file format (pdf, Postscript, etc.). Bi-leveldigital printing machine 102 has a plurality of fixed print heads (notshown) each having a plurality of fixed nozzles (not shown) that canprint a single sized dot or no dot as the paper passes under thenozzles. Raster image processor 104 has an interpretation module 106 anda rendering module 108. As is well known in the art, interpretationmodule 106 and rendering module 108 have computer instructions or codeto produce an unscreened raster image file 110 from input file 80 thatis in a non-raster image format (for example, pdf). If input file 80 isa raster file, then input file 80 requires only raster processes, suchas scaling and color conversion, to produce unscreened raster image file110. Examples of conventional bi-level digital printing systems having adigital printing machine and a raster image processor are the HP®Indigo® 20000 digital press sold by Hewlett-Packard Company(www8.hp.com/us/en/commercial-printers/indigo-presses/20000.htm); theKODAK NEXPRESS SX2700 digital press sold by Ricoh Corporation(http://rpp.ricoh-usa.com/products/production-printers/cutsheet/kodak-nexpress);and the Xerox® Color J75 digital press sold by Xerox Corporationwww.xerox.com/digital-printing/printers/digital-press/xerox-j75/enus.html).

FIG. 2 shows a generic unscreened raster image file 110 produced byrendering module 108 (w pixels wide by h lines high). Each pixel ofunscreened raster image file 110 has a continuous tone value (forexample, 0-1023 for 10 bit tone values) for each colorant of Cyan,Magenta, Yellow and black (CMYK). In order to print unscreened rasterimage file 110 on bi-level digital printing machine 102, raster imageprocessor 104 further comprises a screening module 114 (FIG. 1) that hascomputer instructions to screen or convert the continuous tone value ofeach pixel of unscreened raster image file 110 to a print level value (0or 1) stored in an output bitmap file 116 (FIG. 1) using a well knownhalf-toning algorithm such as threshold screening or AM screening.

FIG. 3 shows a high level flow chart of conventional screening module114 of raster image processor 104. For each pixel on each line of aninput unscreened raster file 110, whose coordinates are X and Y, thecontinuous tone value is processed into a 1-bit output value by ahalf-toning algorithm.

Multi level printing machines are being developed where a nozzle canprint more than two (2) levels for each printed pixel, such as a fourlevel machine. For example, in a four level machine, each nozzle canprint no dot, a small dot, a medium dot or a large dot thereby allowingfor a much finer quality print. FIG. 4 shows a generic screened 2-bitoutput bitmap file for a 4-level digital printing machine. Each pixelhas a value of 0-3, with a set of raster data for each printing ink orcolorant.

FIG. 5 shows a conventional way of partitioning the tone ranges in equalparts for a 4-level press having 3 dot sizes. One disadvantage of suchcontiguous sectioning of the printed tone range into equal parts, onefor each output tone level for each colorant, is an artifact offlattening or visible loss of screening at the boundaries between thelevels.

FIG. 6 is a graph illustrating a response that one would expect for aperfectly built and correctly operating or ideal digital printingmachine. For such an ideal press, an input tone value of 33.3% from theunscreened raster file results in a patch of small size dots having ameasured print strength of 33.3 percent. However, no digital printingmachine operates in an ideal manner.

FIG. 7 is a graph illustrating a response for a digital printing machinethat behaves in a non-ideal manner. In this example, an input tone valueof 33.3% from the unscreened raster file results in a patch of smallsize dots having a measured print strength of 45 percent and not 33.3percent. Further, an input tone value of 66.7 percent results in a patchof all medium size dots having a measured print strength of 55 percentand not 66.7 percent. As such, unwanted artifacts in the print arecreated as a result of the print heads of the digital printing machineproducing a stronger or lighter intensity level for any continuous tonevalue of the unscreened raster file. These improper values and theintermediate values need to be carefully compensated.

Another drawback with conventional screening modules is the inability tocompensate for variations in print strength of individual inkjet nozzlesexcept by modifying the continuous tone input data. Aside from thedifficulty in precisely specifying such corrections, for largecompensations this can reduce the number of available printed screenedtone levels, resulting in undesirable tone banding artifacts. Thisinvention allows for an additional form of compensation that does notreduce the number of printed tone levels, while also simplifying thespecification of the individual compensations.

SUMMARY OF THE INVENTION

One object of the present invention is to provide a raster imageprocessor and method thereof that produces a high quality multi-levelscreened output bit map file for digital printing machines that easily,accurately, and precisely removes the flattened tone contour artifacts.

Another object of the present invention is to provide a raster imageprocessor and method thereof that removes unwanted artifacts in theprint created as a result of the print heads of the digital printingmachine producing a stronger or lighter intensity levels.

Another object of the present invention is to provide a raster imageprocessor and method thereof that produces a high quality multi-levelscreened output bit map file for digital printing machines that employsany bi-level half-toning algorithm.

Another object of the present invention is to provide a raster imageprocessor and method thereof that produces a high quality multi-levelscreened output bit map file for digital printing machines with anarbitrary number of gray levels, not limited to a power of 2.

Another object of the present invention is to provide a raster imageprocessor and method thereof that produces a high quality multi-levelscreened output bit map file for digital printing machines whosemultiple gray levels are extremely far from being equally spaced in thetone range, thus giving expanded design leeway to designers of newdigital printing machines.

Another object of the present invention is to provide a raster imageprocessor and method thereof that produces a high quality multi-levelscreened output bit map file for digital printing machines with acalibration method and system that is straightforward, accurate,powerful, and quick, enabling rapid adaptation to changing printconditions, print heads, nozzles, electronics, and other physicalvarying factors.

Another object of the present invention is to provide a method ofcompensation of variations of individual print positions or nozzles,that does not reduce the number of printed tone levels, while alsosimplifying the specification of the individual compensations.

In one embodiment, the present invention is a system and method ofcalibration, screening, and compensation for multiple gray-level digitalpresses. Unequal quantization of the input range is employed withcompensated overlapping of sub-ranges. Multiple instances of bi-levelscreening algorithms, tone modification functions, and a recombinationalgorithm are employed to produce calibrated screening on individualtone ranges. The method works with any bi-level screening algorithm anddevices with any number of gray-levels. Quality imaging results fromhigh detail, high tonal accuracy, low screening noise, and lack ofprinted artifacts. Dynamic re-calibration is facilitated. Theelimination of the constraint of evenly spaced gray-levels also hasadvantages of cost and yield for both print head fabricators as well asdigital press manufacturers. Multiple implementations of the system andmethod are given for both hardware and software embodiments of theinvention. The present invention, which comprises a print profile foreach colorant, is extended to further comprise additional printprofiles, as needed, specifying the print characteristic of a single orgroup of aberrant nozzles. The present invention, which comprises aprint profile for each colorant, is extended to further compriseadditional print profiles, as needed, specifying the printcharacteristic of a single or group of aberrant nozzles.

BRIEF DESCRIPTION OF THE DRAWINGS

The following description of the invention will be further understoodwith reference to the accompanying drawings, in which:

FIG. 1 is a high level block diagram showing the architecture of aconventional raster image processor used to produce a conventionaloutput bit map file for a bi-level digital printing machine.

FIG. 2 illustrates a conventional raster image file produced by aconventional rendering modules having a plurality of printable positionsof a page defined by pixel location, line number, and CMYK value.

FIG. 3 shows a high level flow chart of a conventional screening moduleof a rip. For each pixel on each line of an input unscreened rasterfile, whose coordinates are X and Y, the continuous tone value isprocessed into a 1-bit output value via a half-toning algorithm.

FIG. 4 illustrates a conventional screened bit map output file stored ina bitmap memory device for each of the colorants Cyan, Magenta, Yellow,and Black for printable positions of a page defined by pixel locationand line number. Each of the printable positions of the bit map has a4-level output value (0-3) indicative of no dot, a small dot, a mediumdot, and a large dot.

FIG. 5 illustrates a conventional full tone range for a first coloranthaving three equal tonal sub-ranges corresponding to small, medium, andlarge size dots, respectively.

FIG. 6 is a graph illustrating a response that one would expect for aperfectly built and correctly operating or ideal digital printingmachine.

FIG. 7 is a graph illustrating a response for a digital printing machinethat behaves in a non-ideal manner.

FIG. 8 is a high level block diagram showing the architecture of araster image processor according to the present invention used toproduce a bit map output file for a digital printing machine capable ofprinting multiple levels such as a no dot level, a small dot level, amedium dot level, and a large dot level.

FIG. 9 is a high level block diagram showing the Screening Moduleaccording to the present invention comprising a Calibration Module and aPixel Processing Module comprising a Tone Sub-range sub-module, aBoundary Shifting sub-module, an Overlap sub-module, a Tone Modificationsub-module, and an Output sub-module.

FIG. 10 is a high level flow chart showing the operation of theScreening Module according to the present invention.

FIG. 11 is a high level flow chart showing the operation of the pixelprocessing module of the screening module according to the presentinvention.

FIG. 12 is a high level flow chart showing the operation of thecalibration module of the screening module.

FIG. 13 is a high level flow chart showing an example of the process ofthe Calibration Sub-module.

FIG. 14 illustrates a test pattern of the calibration module.

FIG. 15 illustrates a digital press profile according to the presentinvention.

FIG. 16 illustrates a full tone range for a first colorant comprisingthree tonal sub-ranges corresponding to a first printable tone level(for example, a small size dot), a second printable tone level (forexample, a medium size dot), and a third printable tone level (forexample, a large size dot), respectively, with the tonal sub-rangesshifted.

FIG. 17A illustrates a tone modification function for a first printabletone level (for example, a small size dot) after transition pointshifting according to the present invention.

FIG. 17B illustrates a tone modification function for a second printabletone level (for example, a medium size dot) after transition pointshifting according to the present invention.

FIG. 17C illustrates a tone modification function for a third printabletone level (for example, a large size dot) after transition pointshifting according to the present invention.

FIG. 18 is a high level flow chart showing the process of raster imageprocessor according to the present invention.

FIG. 19 is a flow chart showing the operation of the Screening Moduleaccording to the present invention using example measurements.

FIG. 20 is a flow chart showing the process of the tone modificationsub-module of the pixel processing module.

FIG. 21 is a flow chart showing an example of the process of the tonemodification sub-module with example calculations.

FIG. 22 illustrates solid patches of large dots which may be purposelyoversized to enable solid coverage and may require additionallinearization using conventional dot gain compensation methods.

FIG. 23 illustrates a non-linear dot area response curve and its inversefunction for input compensation.

FIG. 24 is a flow chart showing the operation of the pixel processingmodule.

FIG. 25 is a flow chart of example pseudo code showing the operation ofthe pixel processing module.

FIG. 26 is a high level schematic of the pixel processing module of thescreening module shown in a hardware implementation for discrete logic,ASIC chips, FPGAs, etc, with threshold matrix or supercell type ofscreening.

FIG. 27 is a high level schematic of the output sub-module of thescreening module according to the present invention shown in a hardwareimplementation for discrete logic, ASIC chips, FPGAs, etc, where eachoutput tone value is assigned a level of 0, 1, 2, or 3 corresponding tono dot, small dot, medium dot, and large dot, respectively.

FIG. 28 is a high level schematic of the pixel processing module of thescreening module shown in a hardware implementation for discrete logic,ASIC chips, FPGAs, etc, for an error diffusion type of screening.

FIG. 29 is a high level schematic of one implementation of a tonemodification function in hardware suitable for discrete logic, ASICchips, FPGAs, etc.

FIG. 30 is a block diagram illustrating an alternate implementation of atone modification function employing a look-up table in memory, suitablefor a hardware or a software implantation, comprising pre-computed tonemodification values for a single printable tone level (for example, asmall size dot, a medium size dot, or a large size dot).

FIG. 31 is a high level flow chart showing the operation of a firstembodiment of the overlap module with simple overlap.

FIG. 32 is a graph showing a full tone range for a first colorantcomprising three equally spaced tonal sub-ranges corresponding to asmall dot size level, a medium dot size level, and a large dot sizelevel, respectively, with the second tonal sub-range overlapping thefirst tonal sub-range and the third tonal sub-range overlapping thesecond tonal sub-range.

FIG. 33 illustrates a full tone range for a first colorant comprisingthree tonal sub-ranges corresponding to a first printable tone level(for example, a small size dot), a second printable tone level (forexample, a medium size dot), and a third printable tone level (forexample, a large size dot), respectively, with shifting and simpleoverlapping of the tonal sub-ranges.

FIG. 34A is a graph of a tone modification function for the firstprintable tone level (for example, a small size dot) of a first colorant(for example, Cyan) with shifting and simple overlapping;

FIG. 34B is a graph of a tone modification function for the secondprintable tone level (for example, a medium size dot) of a firstcolorant (for example, Cyan) with shifting and simple overlapping.

FIG. 34C is a graph of a tone modification function for the thirdprintable tone level (for example, a large size dot) of a first colorant(for example, Cyan) with shifting and simple overlapping.

FIG. 35 is a high level flow chart showing the process of a secondembodiment of the overlap module with shifting and bi-directionaloverlapping.

FIG. 36 is a graph showing a full tone range for a first colorant (forexample, Cyan) comprising three equally spaced tonal sub-rangescorresponding to a first printable tone level (for example, a small dotsize), a second printable tone level (for example, a medium dot size),and third printable tone level (for example, a large dot size),respectively, with the second tonal sub-range bi-directionallyoverlapping the first tonal sub-range and the third tonal sub-rangebi-directionally overlapping the second tonal sub-range.

FIG. 37A is a graph of a tone modification function for the firstprintable tone level (for example, a small size dot) with shifting andbi-directional overlapping.

FIG. 37B is a graph of a tone modification function for the secondprintable tone level (for example, a medium size dot) with shifting andbi-directional overlapping.

FIG. 37C is a graph of a tone modification function for the thirdprintable tone level (for example, a large size dot) with shifting andbi-directional overlapping.

FIG. 38 is an example of calibration and screening parametercalculations for a single colorant;

FIG. 39 is a rendered unscreened image of a test picture in CMYK.

FIG. 40 is an image of the Cyan separation of the test picture of FIG.39.

FIG. 41 is an image of the Magenta separation of the test picture ofFIG. 39.

FIG. 42 is an image of the Yellow separation of the test picture of FIG.39.

FIG. 43 is an image of the Black separation of the test picture of FIG.39.

FIG. 44 is an image of the test picture for the separation Cyan (FIG.40) after processing by the small level tone modification function.

FIG. 45 is an image of the test picture for the separation Cyan (FIG.40) after processing by the medium level tone modification function.

FIG. 46 is an image of the test picture for the separation Cyan (FIG.40) after processing by the large level tone modification function.

FIG. 47 is an image of the test picture for the tone modified Cyanseparation (FIG. 44) after processing by a 1-bit half-toning algorithm.

FIG. 48 is an image of the test picture for the tone modified Cyanseparation (FIG. 45) after processing by a 1-bit half-toning algorithm.

FIG. 49 is an image of the test picture for the tone modified Cyanseparation (FIG. 46) after processing by a 1-bit half-toning algorithm.

FIG. 50 is an image for the separation Cyan after combining thehalf-toned images of the separation Cyan of the small dots (FIG. 47),medium dots (FIG. 48), and large dots (FIG. 49).

FIG. 51 is an image for the separation Magenta after combining thehalf-toned images of the separation Magenta of the small dots, mediumdots, and large dots.

FIG. 52 is an image for the separation Yellow after combining thehalf-toned images of the separation Yellow of the small dots, mediumdots, and large dots.

FIG. 53 is an image for the separation Black after combining thehalf-toned images of the separation Black of the small dots, mediumdots, and large dots.

FIG. 54 is a single CMYK composite image composed of the four combinedoutput images of FIGS. 50-53.

FIG. 55 is an extremely high level zoom of a small portion of the singleCMYK composite image of FIG. 54 based upon calibrated tonal range outputlevels of 0%, 45%, 75%, and 100%.

FIG. 56 shows the black separation of the CMYK image of FIG. 55.

FIG. 57 is an extremely high level zoom of a small portion of a singleCMYK composite image after calibration and compensation after a drasticchange of the printing levels (for whatever reason) to 0%, 25%, 50%, and100%.

FIG. 58 shows the black separation of the CMYK image of FIG. 57.

FIG. 59A is a digital press profile for a normal nozzle or group ofnozzles.

FIG. 59B is a digital press profile for an aberrant nozzle or group ofaberrant nozzles.

FIG. 60A illustrates a full tone range for a first colorant from anormal nozzle comprising three tonal sub-ranges corresponding to a firstprintable tone level (for example, a small size dot), a second printabletone level (for example, a medium size dot), and a third printable tonelevel (for example, a large size dot), respectively.

FIG. 60B illustrates a full tone range for a first colorant from anaberrant normal nozzle comprising three tonal sub-ranges correspondingto a first printable tone level (for example, a small size dot), asecond printable tone level (for example, a medium size dot), and athird printable tone level (for example, a large size dot),respectively.

FIG. 61A shows the tone modification function for the first printabletone level for a normal nozzle or group of nozzles.

FIG. 61B shows the tone modification function for the second printabletone level for a normal nozzle or group of nozzles.

FIG. 61C shows the tone modification function for the third printabletone level for a normal nozzle or group of nozzles.

FIG. 62A shows the tone modification functions for the first printabletone level for an aberrant nozzle or group of nozzles.

FIG. 62B shows the tone modification function for the second printabletone level for an aberrant nozzle or group of nozzles.

FIG. 62C shows the tone modification function for the third printabletone level for an aberrant nozzle or group of nozzles.

FIG. 63A shows a print simulation of a test image containing photos andprocess color ramps for the case when all nozzles are pristine orfunctioning normally.

FIG. 63B shows a print simulation of the test image for the case whenthere are aberrant nozzles.

FIG. 64A shows a print simulation of the test image for the case whenall nozzles are pristine but the compensation of the invention is ineffect nevertheless.

FIG. 64B shows a print simulation of the test image for the case whenthere are aberrant nozzles and the compensation of the invention is ineffect.

FIG. 65A shows a closeup of FIG. 63A (Pristine) for all separations.

FIG. 65B shows a closeup of FIG. 63A (Pristine) for just the Magentaseparation.

FIG. 66A shows a closeup of FIG. 63B (Aberrant nozzles) for allseparations.

FIG. 66B shows a closeup of FIG. 63B (Aberrant nozzles) for just theMagenta separation.

FIG. 67A shows a closeup of FIG. 64A (just Compensation) for allseparations.

FIG. 67B shows a closeup of FIG. 64A (just Compensation) for just theMagenta separation.

FIG. 68A shows a closeup of FIG. 64B (Aberrant with Compensation) forall separations.

FIG. 68B shows a closeup of FIG. 64B (Aberrant with Compensation) forjust the Magenta separation.

FIG. 69 shows an extreme closeup of FIG. 68B (Aberrant with Compensationfor just the Magenta separation) with the image horizontally centered onthe left-right transition from normal to aberrant nozzles.

DESCRIPTION OF THE INVENTION

Referring to FIG. 8, a system 801 according to the present inventioncomprises a raster image processor 800 connected with a multi leveldigital printing machine 850. In the embodiment shown, digital printingmachine 850 is a four (4) printable level machine. In other embodiments,digital printing machine 850 may be more or less than a four (4)printable level machine. Raster image processor 800 generally comprisesa computing device 802, a memory device 804 connected with computingdevice 802, an interpretation module 806 stored on memory device 804, arendering module 808 stored on memory device 804 adapted to produce anunscreened raster image file 810, and a screening module 812 adapted toproduce a screened output bit map 814. Computing device 802 may be oneor more of any type of presently known or futurely developedcomputational processing device, including but not limited, to centralprocessing units, microprocessors, and graphic processing units. Memorydevice 804 may be any type of memory device capable of storing computerinstructions or code. Interpretation module 806 comprises a set of wellknown computer instructions or code stored on memory device 804 tointerpret input file 80 describing the page (not shown) to be printed.Rendering module 808 comprises a set of well known computer instructionsor code stored on memory device 804 to produce unscreened raster imagefile 810 specifying a continuous tone value for a first, second, third,and fourth colorant (CMYK) value in the range of 0-1023 (in the case ofa 10 bit tone) for each printable position on the page (not shown). Aswill be described herein, screening module 812 comprises a plurality ofinstructions to convert each of the continuous tone values to a four (4)level output bit map 814, namely, a tone value of 0, 1, 2 or 3 in amanner that significantly reduces contour artifacts and is easily,accurately, and precisely compensated. The term “module” means computerinstructions or code that may be implemented in software or hardware.Such computer instructions or code may be programmed in any presently orfuturely developed programming language such as C or C++ for most typesof computing devices and CUDA® for NVIDIA® graphic processing units. Aswill be described more fully herein, screening module 810 may beimplemented as software stored on memory device 804 or discrete circuithardware directed connected with computing device 102 and/or digitalprinting machine 850.

Referring to FIG. 9, screening module 812 generally comprises acalibration module 902, a tone sub-range module 906, a boundary shiftingmodule 908, and a pixel processing module 904 comprising a tonemodification sub-module 912, an inverse compensation sub-module 914, andan output sub-module 916. In another embodiment of the invention,screening module 812 may further comprise an overlap module 910.

Referring to FIG. 10, a high level flow chart shows the process ofscreening module 812 for digital printing machine 850 (FIG. 8). In thisexample, input file 810 from rendering module 808 may be either acomposite file containing all colorants or separate files one for eachcolorant. As indicated by step 1002, screening module 812 initializesvariables X and Y to zero. As indicated by step 1004, screening module812 is configured to obtain the continuous tone value 1010 for thecurrent X-Y position 1006. As indicated by step 1008, continuous tonevalue 1010 is processed by pixel processing module 1008 to produced amulti bit output value 1012 for X-Y position 1006. For example, a valueof 575 from a 10 bit continuous tone range of input file 810 fromrendering module 808 at X-Y position 1006 is processed by pixelprocessing module 904 to generate a two bit output 1012 of values 0, 1,2 or 3. As indicated by step 1014, position X is incremented to point tothe next pixel to the right. As indicated by step 1016, screening module812 determines if the rightmost limit of X exceeds the raster width. Ifnot, control is returned where the next X-Y position is processed bypixel processing module 904 to produce the next two bit output 1012. Ifthe rightmost limit of X exceeds the raster width then, as indicated bystep 1018, screening module 812 sets the position of X to the leftbeginning of the next line Y. As indicated by step 1020, screeningmodule 812 is configured to determine if the last line Y has beenprocessed and if so, ends execution of the module. If not, control isreturned where the next X-Y position is processed by pixel processingmodule 904 to produce the next two bit output 1012.

Referring to FIG. 11, where a high level flow chart shows the operationof pixel processing module 904 according to the present invention for afour-level digital printing machine 850. As indicated by a block 1102, acurrent X and Y printable position is input to each of bi-levelhalf-toning algorithms 1110, 1112, and 1114 of output sub-module 916.The continuous tone value corresponding to the current X and Y positionfrom input file 1010, for each of the four (4) colorants, is the inputvalue to each of first, second, and third tone modification functions1104, 1106, and 1108 of tone modification sub-module 912. The outputfrom first, second, and third tone modification functions 1104, 1106,and 1108 are then each passed through an inverse compensation functionappropriate for that colorant and dot size from the Inverse Compensationmodule 914. The outputs of the compensation functions are the inputs tobi-level half-toning algorithms 1110, 1112, and 1114, respectively, thatgenerate three one bit output values 1116, 1118, and 1120, each having avalue of 0 or 1. As indicated by block 1122, these three one bit outputvalues are combined by Boolean logic to produce a single 2-bit outputvalue 1012 (0, 1, 2 or 3) that is stored in output bit map 814 (FIG. 8).

Referring to FIG. 12, a high level flow chart shows the process ofcalibration module 902. Calibration module 902 comprises a set ofinstructions 1202 to create a test pattern for each colorant comprisinga first test patch having only a first printable tone level (forexample, only small size dots), a second test patch having only a secondprintable tone level (for example, only medium size dots), and a thirdtest patch having only a third printable tone level (for example, onlylarge size dots). Calibration module 902 further comprises a set ofinstructions 1204 to print the test patterns for each colorant.Calibration module 902 further comprises a set of instructions 1206 tomeasure the optical strength of each of the first, second, and thirdtest patches of each colorant of test pattern 1402 using optical densityas the measurement and to store these values in digital press profile852 (FIGS. 8 and 15) for use as needed. Calibration module 902 furthercomprises a set of instructions 1208 to convert the measurements of eachof the first, second, and third test patches to an equivalent dot areavalue using a well known Murray-Davies equation(www.xrite.com/documents/apps/public/whitepapers/Ga00005a.pdf) thatconverts from optical density to percentage dot area as follows:

${{percentage}\mspace{14mu} {dot}\mspace{14mu} {area}\mspace{14mu} \left( {0\text{-}100\%} \right)} = {\frac{1 - {10^{\bigwedge}\left( {- {Dtone}} \right)}}{1 - {10^{\bigwedge}\left( {{- D}\; \max} \right)}} \times 100}$

where Dmax represents the measured maximum optical density, and Dtonerepresents the measured density of a patch for which to produce thepercentage dot area.

Example densities: 0.0 0.479 1.08 2.5---->0 67% 92% 100%

Example2 densities 0.0 0.1752 0.4735 2.5---->0 33% 67% 100%

Referring to FIGS. 13 and 14, where an example is given for the processof calibration module 902. As indicated by block 1302, calibrationmodule 902 comprises a set of instructions to create a test patternhaving twelve test patches as shown in FIG. 14 (3 printable levels ordot sizes each, for each of the four colorants, CMYK). The three (3) dotsizes may be small, medium, and large dots or other dot sizes.Calibration module 902 further comprises a set of instructions 1304 toprint the test pattern. Calibration module 902 further comprises a setof instructions 1306 to measure the optical strength of each of thetwelve test patches using optical density as the measurement. In theexample shown, for the colorant Cyan, the measured density is 0.475 forthe first printable tone level of digital printing machine 850 (forexample, small size dots); 1.08 for the second printable tone level ofdigital printing machine 850 (for example, medium size dots), and 2.5for the third printable tone level of digital printing machine 850 (forexample, large size dots). Also shown are optical densities values forthe colorants Magenta, Yellow, and Black. The optical density for eachof the first, second, and third test patches of each colorant isconverted to an equivalent dot area using the Murray-Davies equation. Inthe example shown, Cyan has an equivalent dot area of 67% for the firstprintable tone level (for example small size dots), 92% for the secondprintable tone level (for example, medium size dots), and 100% for thethird printable tone level (for example, large size dots). The opticaldensity is measured using a well known densitometer such as the X-RiteeXact available from X-Rite, Inc., 4300 44th St. SE, Grand Rapids, Mich.49512 U.S.A. (www.xrite.com), or a similar device, that may be part ofdigital printing machine 850 or a separate machine connected with rasterprocessor 800 and digital printing machine 850.

Referring to FIG. 15, where digital press profile 852 (FIG. 8) isfurther illustrated. Data stored in Digital Press Profile 1502 includesmaximum measured densities for all colorants and dot sizes. It alsoincludes curve data points when they are used.

Referring to FIG. 16, tone sub-range module 906 (FIG. 9) comprises a setof instructions configured to create and store a first tonal sub-range1602 corresponding to the first printable tone level of digital printingmachine 850 for each of the four colorants, a second tonal sub-range1610 corresponding to the second printable tone level of digitalprinting machine 850 for each of the four colorants, and a third tonalsub-range 1620 corresponding to the third printable tone of digitalprinting machine 850 for each of the colorants. The sub-ranges may andprobably will be different for each of the colorants. First tonalsub-range 1602 comprises a beginning boundary tone value 1604 and anending boundary tone value 1606 defining a first tone range span 1608.Second tonal sub-range 1610 comprises a beginning boundary tone value1612 and an ending boundary tone value 1614 defining a second tone rangespan 1616 and a first transition tone value 1618 to be the value of bothending boundary tone value 1606 of first tonal sub-range 1602 andbeginning boundary tone value 1612 of second tonal sub-range 1610. Thirdtonal sub-range 1620 comprises a beginning boundary tone value 1622 andan ending boundary tone value 1624 defining a third tone range span 1626and a second transition tone value 1628 to be the value of both endingboundary tone value 1614 of second tonal sub-range 1610 and beginningboundary tone value 1622 of third tonal sub-range 1620.

With continued reference to FIG. 16, boundary shifting module 908generally comprises a set of instructions to shift the positions offirst and/or second transition tone values 1618 and 1628 depending uponthe calibration data of digital printing machine 850 from calibrationmodule 902 stored in digital press profile 852. For example, boundaryshifting module 908 may comprise a set of instructions that shift theposition of first transition tone value 1618 so that, for example, firsttone range span 1608 is different from second tone range span 1616. Byway of further example, boundary shifting module 908 may comprise a setof instructions that shift the position of second transition tone value1628 so that second tone range span 1616 is different from third tonerange span 1626. Boundary shifting module 908 further comprises a set ofinstructions to set the first transition tone value 1618, for a givencolorant, using the measured density of the patch of small size dots forthe colorant and the highest measured optical density of the test patchof large size dots for the colorant as the Dmax value used in theMurray-Davies equation. Boundary shifting module 908 further comprises aset of instructions to set the second transition tone value 1628, for agiven colorant, using the measured density of the patch of medium sizedots for the colorant and the highest measured optical density of thetest patch of large size dots for the colorant as the Dmax value used inthe Murray-Davies equation.

Referring to FIGS. 17A-17C, where the process of tone modificationsub-module 912 and tone modifications 1104, 1106 and 1108 (FIG. 11) isillustrated for an example where first and second transition tone values1618 and 1628 (FIG. 16) are set to 48% and 70%, respectively, byboundary shifting module 908. As shown by FIG. 17A, tone modificationsub-module 912 comprises a set of instructions to create or producefirst tone modification function 1104 for the first printable tone levelthat is used for each colorant (CMYK). For example, an input tone valueof 24% would be modified to a continuous tone value of 50% and an inputtone value of 48% or higher would be modified to a value of 100%. Asshown by FIG. 17B, tone modification sub-module 912 further comprises aset of instructions to create or produce a second tone modificationfunction 1704 for a second printable tone level that is used for eachcolorant (CMYK). For example, an input tone value of 48% or less wouldbe modified to a value of 0%, input tone values of 70% or higher wouldbe modified to values of 100% and input values between 48% and 70% wouldbe modified to values between 0% and 100%. As shown by FIG. 9C, tonemodification sub-module 912 comprises a set of instructions to produce athird tone modification function 1706 for a third printable tone levelthat is used for each colorant (CMYK). For example, an input tone valueof 70% or lower would be modified to a continuous tone value of 0% andan input tone value of greater than 70% would be modified to valuesbetween 0% and 100%.

Referring to FIG. 18, where a high level flow chart shows a method ofscreening module 812. As indicated by block 1802, tone sub-range module906 comprises a step of producing for each colorant, first, second, andthird tonal sub-ranges corresponding to the first, second, and thirdprintable tone levels, respectively, having first and second transitiontone values. As indicated by block 1804, boundary shifting module 908comprises a step of shifting the position of first transition tone value1618 and second transition tone value 1628 so that the first tone rangespan is different from the second tone range span, and to set first andsecond transition tone values 1618 and 1628, for each colorant, by usingthe highest measured optical density of the test patches of test pattern1402 (FIG. 14) of digital printing machine 850 (FIG. 8) for the Dmaxvalue used in the Murray-Davies Equation. As indicated by block 1806,tone modification sub-module 912 comprises a step of producing first,second, and third tone modification functions for the first, second, andthird tonal sub-ranges, respectively. As indicated by block 1808, outputsub-module 916 comprises a step of producing a single multi-bit outputvalue corresponding to each colorant for each printable position on thepage by using the modified tone value of the first, second, and thirdtone modification functions as the inputs to a bi-level half-toningalgorithm.

Referring to FIG. 19, where an example of the method of screening module812 is illustrated. As indicated by a block 1902, tone sub-range module906 comprises a step of creating or producing first, second, and thirdtonal sub-ranges 1602, 1610, and 1620 (FIG. 16), initially equallyspaced, whose beginning and ending boundary tone value pairs arerespectively, 0% and 33.3%, 33.3% and 66.7%, and 66.7% and 100.0%. Firstand second transition tone values 1618 and 1628 are thus initially 33.3%and 66.7%, respectively. As indicated by block 1904, boundary shiftingmodule 908 comprises a step of setting first and second transition tonevalues 1618 and 1628 to 67% and 92% based on the measurements shown indigital press profile 852 (FIG. 15) of 0.475 and 1.08 for the testpatches for small and medium dots, respectively, using the Murray-Davieswith a DMax value of 2.5, shown by instructions 1308 of calibrationmodule 902 (FIG. 13). As indicated by a block 1906, tone modificationsub-module 912 comprises a step of creating the first, second, and thirdtone modification functions stored in the form of three 10-bit lookuptables. This process will be shown in two more levels of detail in FIGS.20 and 21, containing a descriptive flowchart and pseudo-code usingexample measurements, respectively. As indicated by a block 1908, outputsub-module 916 comprises a step of producing a single multi-bit outputvalue corresponding to the first colorant for each printable position onthe page by using the modified tone values of first, second, and thirdtone modification functions as the input to a bi-level half-toningalgorithm. This process will be shown in two more levels of detail inFIGS. 24 and 25, containing a descriptive flowchart and pseudo-codeusing example measurements, respectively. The effect of this step inblock 1908, when looked at for the whole image sets of small, medium,and large 1-bit data as a whole is to merge the images together as onewould a set of image masks one on top of another. Where there is a maskbit value of 1, that data and level is used; where there is a 0 value,whatever data on the lower mask levels is allowed to appear.

Referring to FIG. 20, where the process of tone modification sub-module912 is shown in greater detail with example calculations. Step 2002summarizes the function of creating or producing the tone modificationfunctions and their inputs and outputs as previously described inconnection with FIGS. 17A-17C. Step 2014 marks the start of loops oriterations describing the calculations to produce a tone modificationfunction's particular modified tone value for a specific input value. Asindicated by a decisional block 2004, tone modification sub-module 912comprises a set of instructions to determine if the input tone value ofthe first tone modification function is less than the beginning boundarytone value of the first tonal sub-range. If so, control is passed to ablock 2006 where tone modification sub-module 912 comprises a set ofinstructions to assign the continuous modified tone value to be thevalue of zero percent (0%). If not, control is passed to a decisionalblock 2008 where tone modification sub-module 912 comprises a set ofinstructions to determine of the input tone value of the first tonemodification function is greater than the ending boundary tone value ofthe first tonal sub-range. If so, control is passed to a block 2010where tone modification sub-module 912 comprises a set of instructionsto assign the continuous modified tone value to be the value of onehundred percent (100%). If not, control is passed to block 2012, wheretone modification sub-module 912 comprises a set of instructions toassign the continuous modified tone values for input tone values thatfall between the first tonal sub-range's beginning and ending boundarytone values. Conventional linear interpolation is used, mapping thewithin-boundaries input tone range to the full tone range 0 through 100%with values given by a linear interpolation formula defined by: outputtonevalue=((input_tone_value−starting_tone_value)*100)/(ending_tone_value−starting_tone_value)).

Referring to FIG. 21, where example pseudo code is shown to calculatethe 1024 values for the lookup tables for each of the three tonemodification functions. A single loop is used for all three tables. Thetonal sub-ranges are for the Cyan colorant shifted based on the measuredtone densities. Step 2102 creates an iterating integer index, “i”. Step2104 calculates a floating point percentage value in the range 0 through100, based on the value of “i”. Step 2106 sets the value for the ithentry in the first or small dot lookup table to be either 1023,indicative of 100%, or a fractionally lower value depending on thefloating point percentage. Step 2108 sets the value for the ith entry inthe second or medium dot lookup table to be one of the values 0, 1023,or a fractionally intermediate value between 0 and 1023, depending onwhether the floating point percentage is below, above, or within thetonal sub-range, respectively. Step 2110 sets the value for the ithentry of the lookup table for the third or large dot lookup table to beeither 0 or a fractionally intermediate value between 0 and 1023,depending on whether the floating point percentage is below or withinthe tonal sub-range. Step 2112 increments i for the next lookup tableentries. Step 2114 checks for completion by seeing if i has reached 1024indicating that all the entries of indices 0 through 1023 have beencalculated.

Referring to FIG. 22, patches 2202, 2204, and 2206 each show a printedpatch five (5) printing dots wide by six (6) printing dots high, of dotsof increasing sizes and overlap. One dot is shown missing in each ofpatches 2204, 2204, and 2206. The amount of dot area missing decreaseswith increasing dot size. As 100% coverage is reached there isdiminishing increase in dot area. This non-linear effect is similar totraditional “dot gain”.

Referring to FIG. 23, a graph illustrates compensation for thenon-linear response of increasing tone value and a conventional inversefunction used to compensate for it. For example for input tone values inthe proximity of 50% the output tone values as points on curve 2302 arein the proximity of 75%. Compensating for this dot gain, when the systemrequires an output tone value of 50%, the necessary input tone needed istherefore less than 50% or about 20% as shown on inverse function 2304.

Referring to FIG. 24, where a high level flow chart shows the operationof output sub-module 916. Step 2402 gets modified continuous tone valuesproduced from the output of the tone modification functions 1104, 1106,and 1108. Step 2404 processes the modified continuous tone values withbi-level half-toning algorithms producing three 1-bit values. Decisionblocks 2406, 2410, 2414, and 2418 check the values of the three 1-bitvalues to select among multi-bit output values 3, 2, 1, and 0 viastatement blocks 2408, 2412, 2416, and 2420 respectively.

Referring to FIG. 25, where a detailed pseudo code flowchart of pixelprocessing module 904 is shown. Step 2502 creates three Booleanvariables, B1, B2, and B3, for small, medium, and large dots,respectively. For each pixel on the page Step 2504 retrieves thecorresponding continuous tone value from the rendering and thecorresponding threshold matrix value from the screening thresholdmatrix. Step 2506 performs tone modification 1 by selecting a value fromLookUpTable1 based on the continuous tone value from the rendering. Step2506 sets the value of Boolean variable B1 to true if the looked upvalue is greater than the threshold matrix value. Otherwise Step 2506sets the value of B1 to false. Steps 2508 and 2510 similarly set Booleanvariable B2 and B3 using LookUpTable2 and LookUpTable3, respectively,and the continuous tone value from the rendering. Decision block 2512and statement 2514 select 3 as the multi-bit output value if B3 is true.If B3 is false, decision block 2516 and statement 2518 select 2 as themulti-bit output value if B2 is true. If B2 is false, decision block2518 and statement 2524 select 1 as the multi-bit output value if B1 istrue. If B1 is false, statement 2526 selects 0 as the multi-bit outputvalue. Decision block 2522 checks to see if the X-Y position justoperated on is the last one on the page and either ends the module ifthe X-Y position is the last one on the page, or sets the control flowback to step 2504 to proceed with the next pixel to be processed.

Referring to FIG. 26, where a schematic for pixel processing module 904is shown in a hardware implementation suitable for threshold matrixhalf-tone screening. Blocks 2602, 2604, and 2606 show first, second, andthird tone modification functions for the first, second, and thirdprintable tone levels, respectively (for example, small, medium, andlarge dots). Components used in the hardware for tone modificationfunctions 1104, 1106, and 1108 include 10-bit registers to holdscreening parameters, 10-bit subtractors, and 10-bit multipliers.Bi-level half-toning, shown by block 2608, comprises a threshold matrix2610 that produces a threshold value 2611 for a given X-Y coordinate,and a comparator such as 2612 that compares the modified continuous tonevalue with the threshold value 2611 to determine a 1-bit output 2618 forthe small size dots. Comparators 2614 and 2616 use the same thresholdvalue 2611 to compare modified continuous tone values from ToneModification functions 2604 and 2608 to produce 1-bit outputs 2620 and2622 for the medium and large dots, respectively.

Referring to FIG. 27, where a digital logic diagram is shown forproducing multi-bit output 2708 from 1-bit logic levels 2618, 2620, and2622 for small, medium, and large dots, respectively. Sections 2702,2704, and 2706 are 2-bit multiplexers for data flow for the small,medium, and large dots, respectively. Each of 2-bit multiplexers 2702,2704, and 2706 have as inputs selector lines 2710, 2712, and 2714, andinput lines internally labeled A1, A0, B1, and B0. Each 2-bitmultiplexer has two output lines internally labeled A and B. Each 2-bitmultiplexer functions as a two state switch, copying the two logiclevels on inputs A1 and B1 to outputs A and B if its selector line isconnected to a high logic level, or copying the logic levels on inputsA0 and B0 to outputs A and B if its selector line is connected to a lowlogic level. Production of multi-bit output value 2708 is described asfollows. If 1-bit logic level 2622 is high 2-bit multiplexer 2706immediately copies input levels of 11 to its output levels A and B, 0b11in binary or base 2, which is equal to a value of 3 in the common base10 number system. This provides a value of 3 to output value 2708. Iflogic level 2622 is low, A0 and B0 inputs of multiplexer 2706 areselected for the output value 2708. Inputs A0 and B0 inputs ofmultiplexer 2706 are connected to the outputs A and B of 2-bitmultiplexer 2704 and thus receive either the A1 and B1 inputs ofmultiplexer 2704, which have values of 1 and 0, respectively, or theoutputs A and B of multiplexer 2702, depending on the logic level state2620, the logic level for the medium dot.

With continued reference to FIG. 27, 2-bit multiplexer 2702 has itsoutputs A and B selected between the 2-bit values 01 from the A1 and B1inputs or the 2-bit values 00 from the A0 and B0 inputs. In this mannerthe multi-bit output value 2708 is set to one of the four 2-bit binaryvalues 00, 01, 10, or 11, depending on the 3 1-bit logic levels 2618,2620, and 2622. The numbers 00, 01, 10, or 11 interpreted in binary(base-2) have the values 0, 1, 2, and 3 (base 10) respectively.

Referring to FIG. 28, where an alternative hardware for pixel processingmodule 904 is implemented in a manner suitable for an error diffusionalgorithm. Hardware bi-level half-toning modules 2802, 2804, 2806 areshown as implementing an error diffusion algorithm for the half-toningfunction. They must each be initialized at the start of page as is wellknown in the art. Modules 2802, 2804, 2806 operate in parallel, that issimultaneously with each other, each producing a 1-bit value for aparticular dot size. These three 1-bit values are inputs to the 2-bitmultiplexers (FIG. 27).

Referring to FIGS. 29 and 30, two alternative implementations are shownfor the 3 tone modification functions 2602, 2604, and 2606 (FIG. 26).For example, continuous tone input 1010 could have, in the range 0-1023,a value of 2. The implementation of FIG. 29 would perform a subtractionfollowed by a multiplication on the value 2 to produce the modifiedcontinuous tone 1116. The implementation of FIG. 30 would use the value2 as an index into lookup table 3002, retrieving the third value 2802 asthe output value in a single operation.

Referring to FIGS. 31 and 32, in a first embodiment, overlap module 910comprises a set of instructions to overlap the first and second tonalsub-ranges 3202 and 3204 by modifying a beginning boundary tone level3212 of second tonal sub-range 3204 to a value 2% (example) lower thenan ending boundary tone level 3210 of first tonal sub-range 3202.Overlap module 910 further comprises a set of instructions to overlapsecond and third tonal sub-ranges 3204 and 3206 by modifying a beginningboundary tone level 3216 of third tonal sub-range 3206 to have a valueof 2% lower than an ending boundary tone level 3214 of second tonalsub-range 3204.

Referring to FIG. 33, where both shifting and overlapping of acontinuous tonal boundary is illustrated. Shown are first, second, andthird tonal sub-ranges 3302, 3304, and 3306. First tonal sub-range 3302has a beginning boundary tone value 3308 and an ending boundary tonevalue 3310. Second tonal sub-range 3304 has a beginning boundary tonevalue 3312 and an ending boundary tone value 3314. Third tonal sub-range3306 has a beginning boundary tone value 3316 and an ending boundarytone value 3318. First and second transition tone values 3322 and 3324are set at 48% and 70%, respectively. The beginning boundary tone value3312 of second tonal sub-range 3304 has been moved a value of 2% lowerthan the ending boundary tone value 3310 of first tonal sub-range 3302resulting in an overlap of first and second tonal sub-ranges 3302 and3304. Similarly, the beginning boundary tone value 3316 of third tonalsub-range 3306 has been moved a value of 2% lower than the endingboundary tone value 3314 of second tonal sub-range 3304 resulting in anoverlap of second and third tonal sub-ranges 3304 and 3306.

Referring to FIG. 34A-34C, where graphs illustrate tone modificationfunctions for small size dots (FIG. 34A), medium size dots (FIG. 34B),and large size dots (FIG. 34C). The tone modifications for shifting withoverlapping are determined in the same manner as the tone modificationsfor shifting without overlapping (FIGS. 16 and 17).

Referring to FIGS. 35 and 36, where a second embodiment of overlapmodule 910 is shown with bi-directional overlapping. Overlap module 910comprises a set of instructions 3502 to overlap the first and secondtonal sub-ranges 3502 and 3504 by modifying beginning boundary tonelevel 3512 of second tonal sub-range 3504 to a value 2% lower thenending boundary tone level 3510 of first tonal sub-range 3502. Overlapmodule 910 comprises a set of instructions 3504 to overlap the first andsecond tonal sub-ranges by modifying ending boundary tone level of firsttonal sub-range 3502 to a value 2% higher then beginning boundary tonelevel of second tonal sub-range 3504. Overlap module 910 comprises a setof instructions 3506 to overlap second and third tonal sub-ranges 3504and 3506 by modifying beginning boundary tone level 3516 of third tonalsub-range 3506 to have a value of 2% lower than ending boundary tonelevel 3514 of second tonal sub-range 3504. Overlap module 910 comprisesa set of instructions 3508 to overlap second and third tonal sub-ranges3502 and 3504 by modifying ending boundary tone level of second tonalsub-range 3504 to a value of 2% higher then beginning tone level ofthird tonal sub-range 3506.

Referring to FIGS. 37A-37C, where graphs illustrate tone modificationfunctions for small size dots (FIG. 36A), medium size dots (FIG. 36B),and large size dots (FIG. 36C), tone modification function 3702 iscomprised of 3 segments labeled A through C. The value for the modifiedcontinuous tone value for this function is 100 if the input tone valuefalls within segment C. If the input tone value falls within segments Aor B, the value for the modified continuous tone value is a standardlinear interpolation between the two Y values of the endpoints ofsegments A and B, respectively, as is generally known to one skilled inthe art.

Referring to FIG. 38, where example calculations are shown for thescreening parameters used for the tone modification functions, thescreening parameter SmallDotPeak is calculated to have the 10-bitinteger value 685. The Calculation column shows how the values arecalculated. For example, in the case of the SmallDotPeak parameter, theMurray Davies equation is used with density 0.475 and the nominal Dmaxvalue of 2.50 to produce an equivalent dot area value of 67% that isscaled to a 10-bit integer value by dividing by 100 and multiplying by1023 to give result 685.

Referring to FIGS. 39-59, where a visual demonstration of screeningcalibration and compensation for a four gray-level digital printingmachine is illustrated. The native PDF drawings filed with thisapplication are electronically available at the USPTO web site(www.uspto.gov) via PAIR in the SCORE database using the SupplementalContent tab. These native drawings can be zoomed in and out as describedherein. The first step in press control is to calibrate the printprocesses. For traditional lithographic printing, this mainly involvedmeasuring the density of a dark film, as films are used for all inks. Inthe present invention, this includes measuring the print densities ofeach of the process color inks. For multiple gray level digital presses,and specifically for this calibration, this now includes measuring thedensity of solid patches of each of the dot sizes or printable tonelevels of the digital printing machine. Though the scale and power ofcurrent desktop imaging programs is less than employed in currentdigital front ends for digital presses, current desktop imaging programshave excellent visual fidelity are can be used to well illustrate theprocesses of the invention.

Referring to FIG. 39, the Musicians image is used as a renderedunscreened test image or file because it has excellent detail as well asskin tones, which are traditionally hard, yet critical for qualityprinting. The file is small compared to rendered data for a moderndigital press. It is about 6×6 inches with a resolution of 350 dpi. Bycomparison, a digital press today may print 30 inches by 40 inches witha resolution of 1200 dpi. The rendered data for digital press thus hasover 390 times the number of pixels in the Musicians image. Theprocessing is the same, however, and the data processed images areeasier to see with the far smaller Musicians file as rendered data.Also, to make the processes more visible, this calibration demonstrationwill employ FM screening at ⅙th the resolution of what it would be forthe digital press, 200 Ipi versus 1200 Ipi. Error diffusion will beused. There is one final and major difference between this demonstrationon a small image file and a production system on a digital press asoutlined in the invention. For speed and efficiency, each of theinvention embodiments processes a complete pixel by pixel in one pass.For this demonstration, however, at each step of the process data hasbeen collected and made into a visible image suitable for placing intodrawings for illustration. In the following images, examining the fourprocess color ramps about the border of the test image is an excellentway to navigate the process and see what is actually going on afterindividual processing steps of the invention.

Referring to FIG. 40, shown is the rendered unscreened image data forthe separation of Cyan. The ramp for Cyan is shown having extremelysmooth and continuous tone of Cyan from 0 to 100 percent, easilyverified by zooming in.

Referring to FIG. 41, shown is the rendered unscreened image data forthe separation of Magenta. The ramp for Magenta is shown having a smoothand continuous tone of Magenta from 0 to 100 percent.

Referring to FIG. 42, shown is the rendered unscreened image data forthe separation of Yellow. The ramp for Yellow is shown having a smoothand continuous tone of Yellow from 0 to 100 percent.

Referring to FIG. 43, shown is the rendered unscreened image data forthe separation of Black. The ramp for Black is shown having a smooth andcontinuous tone of Black from 0 to 100 percent.

Referring to FIGS. 44-49, the following steps of processing the testimage will be shown for the Cyan separation only. The other processcolors are processed similarly. In actual practice, there will bedifferent measurements and tone modification functions for each of theseparations. FIGS. 44-46 show images of the same rendered data afterbeing processed by the three (3) tone modification functions. The graylevels used for the digital press are not the equidistant ones that alinear tone quantization would employ. Here, for all separations, thesmall, medium, and large dots, indicative of the 3 non-zero gray levelshave been given equivalent dot areas of 45%, 75%, and 100%. This shouldbe clear upon examination of the visible tone ramps. For example, inFIG. 45 the part of the ramp lower than 45% is white (0%) and the partof the ramp above 75% is black (100%).

Referring to FIGS. 47-49, where are images are shown after the data haspassed through the half-toning algorithms. Zooming in on the ramps atpoints 45% and 75% of the way from light to dark is illustrative.Half-toning takes place only within each sub-range. Again, only theseparation of Cyan is shown.

Referring to FIG. 50, where an image of the separation for Cyan is shownafter being processed by the multi-layer combination logic. The four2-bit output levels are represented by the four contone levels 0%, 45%,75%, and 100% both for view ability as well as correspondence to theprinted image. Zooming in on both transition points, 45% and 75%, on theCyan ramp at a zoom of 200% or 300% readily shows both the transitioningat these points, as well as the overlapping. The other separations,after similar processing, are shown in FIG. 51 (Magenta), FIG. 52(Yellow), and FIG. 53 (Black).

Referring to FIG. 54, the four output images (FIGS. 50-53) are nowcombined into a single CMYK composite color image. This image stillcontains only 4 gray levels (3 dot sizes) per separation. Because of thehigh resolution of this image, at low zoom levels, display programsoperating on this document may average it down to lower resolution,making it appear to be continuous tone. Though this removes all thescreening that is to be shown, it has the advantage of showing theinherent visual fidelity of the image, as the zoomed out image looksvirtually indistinguishable from the original CMYK continuous toneimage.

Referring to FIGS. 55 and 56, zooming in on a small portion of CMYKimage (FIG. 55) and the separation for black (FIG. 56) of that zoomshows the calibration and screening details. These images are anextremely high level zoom on a very small portion of FIG. 54 chosen forthe very dynamic tonal changes and detail in this region. At this levelof zoom, on a single separation, the advantages of the invention areeasily seen. The placement of the transition points at the toneequivalency points lets the whole image appear continuous-tone-like,even though the image has only 4 tones. Close examination, or viewingthe histogram, confirms this 4 gray-level nature. The image also showsthe ability of a multi-level digital press to hold detail. The shadingon the wrist employs all three dot-sizes and shows the extremely smoothhand-offs between changes of dot size and changes of dot frequency toproduce visual tone change.

Referring to FIGS. 57 and 58, recall that the tonal range output levelsfor the rendered unscreened test image of FIG. 39 was set at 0%, 45%,75%, and 100% resulting in the high quality screened images of FIGS. 54,55, and 56. To demonstrate the flexibility and efficacy of theinvention, FIGS. 57 and 58 show the same color and black separationzoom-ins as FIGS. 55 and 56, only this time after a re-calibration andcompensation for a drastic change of the printing levels (for whateverreason) to 0%, 25%, 50%, and 100%. The small dots are now much lighterand the medium dots are now much darker. Nevertheless, the images ofFIGS. 57 and 58 are virtually indistinguishable from the images of FIGS.55 and 56, respectively. After careful analysis, especially at evenhigher zoom levels, one sees for example that the middle of the wrist inFIG. 56 is composed of mostly white with some small dots, whereas thatsame portion of the wrist in FIG. 58 is composed of mostly small dotswith some medium dots. Back away, however, and the images rightly becomeindistinguishable.

The calibration, screening, and compensation, shown here for a 4gray-level device, offers digital printing a calibrated and compensatedscreening system with low noise, high accuracy, precise imaging, dynamicre-calibration, and most-importantly, extremely high visual fidelity,making the most use of the inherent capabilities of the new generationof printing machines.

Referring to FIGS. 59A, 59B, 60A, and 60B, a further extension of theinvention involves the ability to compensate for one or more aberrantprint nozzles. The print in the pixel positions of one or more aberrantnozzles appears either lighter or darker than normal nozzles. As theinvention shifts tone ranges based on measurements of solid fields ofeach drop size, all that is needed are additional measurements of solidfields of each drop size for each aberrant nozzle or groups of nozzles.FIG. 59A shows a digital press profile comprising measured densitymeasurements of each colorant printed from a normal nozzle or group ofnozzles. FIG. 59B shows a digital press profile comprising measureddensity measurements of each colorant printed from an aberrant nozzle orgroup of aberrant nozzles. In the case of aberrant nozzles, both thesmall and the medium size dots appear lighter than those from normalnozzles. FIG. 60A shows the tone sub-ranges for normal nozzles, for asingle colorant (black), based on the digital press profile measurementsfor the normal nozzles (FIG. 59A). FIG. 60B shows the new tonesub-ranges for the aberrant nozzles, for a single colorant (black),based on the digital press profile measurements for the aberrant nozzles(FIG. 59B). Automatic computing and use of the new set of tonesub-ranges, results in a set of multi-level output data for the aberrantnozzles that does not appear lighter even though the printed dotsthemselves are lighter. Rather the automatic multi-phase compensationand screening assigns more dots and/or dots of the next larger dot size.This also has the visual effect of producing regions of print thatappear darker. Similarly, by using a new set of shifted tone sub-ranges,aberrant nozzles which are producing darker dots are compensated as theshifted tone sub-ranges produce fewer dots and/or dots of the nextsmaller size for the aberrant nozzles.

Though it is more straight forward to implement the switching toadditional tone modification functions in the context of a softwareembodiment of the invention, it is possible to do so with the examplehardware embodiments as well. This is facilitated when using the saidlookup table implementation of tone modification functions.

Referring to FIGS. 61A, 61B, and 61C, the corresponding set of tonemodification functions are shown for the first, second, and thirdprintable tone levels for normal nozzles.

Referring to FIGS. 62A, 62B, and 62C, the corresponding set of tonemodification functions are shown for the first, second, and thirdprintable tone levels for an aberrant nozzle or group of nozzles.

Referring to FIG. 63A a test image is shown which includes bothphotographs and four tone ramps for the four process ink colorants,Cyan, Magenta, Yellow, and Black. This image, a CMYK continuous toneimage, actually contains only four gray levels for each of thecolorants. It is made from multibit screened data wherein each of thecolorant output values is represented by a 2-bit value 0-3. The visualtone values of these levels are assumed to be equally spaced. Thus eachcolorant contains these 4 monochrome or “gray” levels: 0% (white), 33.3%(a light gray), 67% (a dark gray), and 100% (full black). This simulatedprint image is made by mapping the four different 2-bit values, 0through 3, of the screened data to these four 8-bit tone values, 0, 85,170, and 255. These four 8-bit values are equally spaced, each 85 toneunits apart from the next.

Referring to FIG. 63B the same screened data values for the test imagehas been used to show the effect of aberrant print heads. Specifically,25 tone units, about 10% of the 8-bit 0-255 range, is subtracted fromthe value 85 representing the Small tone value (1), and also from thevalue 170 representing the Medium tone value (2). Thus 8-bit tone levels60 and 145 are used to represent the Small and Medium dots in theaberrant region. The 150 nozzle locations from left to right where thenozzles are aberrant are staggered for the four colorants. Thus one cansee in the tone ramps that the very same screened 2-bit data now appearslighter in staggered approximately 1/10 inch vertical bands, as visiblein both the photographs and the tone ramps.

Referring to FIG. 64A, the image represents the simulated print of thecase where pristine nozzles are again used, and the compensation methodof the invention is in place. This has an effect on the number andplacement of the Small, Medium, and Large output dots. The 8-bit tonevalues representing Small and Medium, 85 and 170, have been restored tothe original equally spaced normal levels. To be noted are the bandswhich appear to be darker within the photos and tone ramps. It is key tocomprehending the compensation method of the invention to understandthat each and every pixel in this image uses only one of the fourequally spaced 8-bit tone levels, 0, 85, 17, and 255. The darkeningappears because the screening has changed. More Medium dots are usedwhere before Small dots were used. Similarly more Large dots are usedwhere before Medium dots were used. This will become clearer withsubsequent further zoomed images of a single colorant.

Referring to FIG. 64B, the image represents the simulated print of thecase where both the lightening, due to aberrant nozzles, is in effect aswell as the darkening, due to the compensated screening changes is ineffect. The simulated print image of 64B thus now appears to be freefrom artifact, the intended and very desirable result. The subsequentimages will visibly reveal how this takes place.

Referring to FIGS. 65A and 65B, a zoom in of a region which wouldcontain a single, would-be aberrant Magenta band is shown. There is nolightening of the individual pixels as well as no change of screening inthe band as this is for the normal nozzle case with no screeningcompensation.

Referring to FIGS. 66A and 66B, this same region is now shown for thecase when the normal screened data is represented by the aberrant tonevalues. FIG. 66A shows the lightened color shift and FIG. 66B with closeexamination reveals the use of screened Small and Medium dots each ofwhich becomes lighter in the aberrant region.

Referring to FIGS. 67A and 67B, this same region is now shown for thecase when the screened data has changed in the aberrant regionrepresented use of the compensation method of the invention, shiftedtone sub-ranges based on newly measured dot densities. FIG. 67A showsthe darkening color shift due to this new screening. FIG. 67B with closeexamination reveals the use of more frequent Medium and Large dots toproduce this darkening. Only the screening pattern has changed; thetones used to represent Small and Medium dots has not. There isindividual continuity of individual dot tones across the regionboundaries.

Referring to FIGS. 68A and 68B, the aberrant region is shown for thecase when both the aberrant nozzles are shown lightened due to use ofthe lighter 8-bit tone values 60 and 145 and the compensated screeningof the invention is in effect causing perceived darkening. FIG. 68Aappears very normal, with the aberrant band appearing neither lighternor darker. FIG. 68B, showing just the Magenta channel appears normal atfirst glance. Further and extreme zoom-in of FIG. 68B will enable boththe lightening and darkening effects to be seen.

Referring to FIG. 69, an extreme zoom of FIG. 68B is shown. It iscentered on the left normal to aberrant vertical transition line. Whenviewed from afar FIG. 69, too, appears to be normal and withoutartifact. Close examination reveals the lightening effect of Small andMedium dots changing between the left and right halves of the image.Examination also reveals that the screening changed across thetransition and that the use of increased numbers of next larger levelpixels has a darkening effect. These two effects effectively cancel eachother out, thus illustrating the invention's method of compensating foraberrant nozzles through the use of altered screening.

While particular embodiments of the invention have been shown anddescribed, it will be obvious to those skilled in the art that changesand modifications may be made without departing from the scope of theclaimed invention.

What is claimed:
 1. A method of generating a screened multi-bit dataoutput file for a digital printing machine having first and secondnozzles that each can print on a page a first printable tone level, asecond printable tone level, and a third printable tone level, from anunscreened raster data file specifying a continuous tone value for afirst colorant for each printable position of the page, the methodcomprising the steps of: (a) creating a first set of tonal sub-rangescorresponding to the first nozzle; said first set of tonal sub-rangescomprising first and second tonal sub-ranges corresponding to the firstand second printable tone levels, respectively, for the first colorant;each of said first and second tonal sub-ranges comprising beginning andending boundary tone values defining first and second tone range spansand a first transition tone value to be both said ending boundary tonevalue of said first tonal sub-range and said beginning boundary tonevalue of said second tonal sub-range; (b) creating a second set of tonalsub-ranges corresponding to the first nozzle; said second set of tonalsub-ranges comprising first and second tonal sub-ranges corresponding tothe first and second printable tone levels, respectively, for the firstcolorant; each of said first and second tonal sub-ranges of said secondset of tonal sub-ranges comprising beginning and ending boundary tonevalues defining first and second tone range spans and a first transitiontone value to be both said ending boundary tone value of said firsttonal sub-range and said beginning boundary tone value of said secondtonal sub-range of said second set of tonal sub-ranges; (c) shifting theposition of said first transition tone value of said second set of tonalsub-ranges so that said first tone range span of said second set oftonal sub-ranges is different from said said first tone range span ofsaid first set of tonal sub-ranges; (d) producing a modified output tonevalue for said first and second sub-ranges of said second set of tonalsub-ranges by first and second tone modification functions,respectively; and (e) producing a single multi-bit output valuecorresponding to the first colorant for each printable position on thepage by using said modified output tone value of said first and secondtone modification functions as inputs to at least one half-toningalgorithm.
 2. The method claim 1, wherein step (a) further comprises thestep of creating a first digital press profile comprising densitymeasurements of the first colorant for each of the first and secondprintable tone levels, corresponding to a normal nozzle.
 3. The methodclaim 2, wherein step (b) further comprises the step of creating asecond digital press profile comprising density measurements of thefirst colorant for each of the first and second printable tone levels,corresponding to an aberrant nozzle.
 4. A method of generating ascreened multi-bit data output file for a digital printing machinehaving first and second nozzles that each can print on a page a firstprintable tone level, a second printable tone level, and a thirdprintable tone level, from an unscreened raster data file specifying acontinuous tone value for a first colorant for each printable positionof the page, the method comprising the steps of: (a) creating a firstprinter profile comprising density measurements for the first colorantfrom the first nozzle; (b) creating a first set of tonal sub-rangesbased upon said first printer profile of the first nozzle; said firstset of tonal sub-ranges comprising first and second tonal sub-rangescorresponding to the first and second printable tone levels,respectively, for the first colorant, based upon said first digitalprint profile; (c) creating a second printer profile comprising densitymeasurements for the first colorant from the first nozzle that aredifferent that the density measurements of the first printer profile;and (d) creating a second set of tonal sub-ranges corresponding to thefirst nozzle; said second set of tonal sub-ranges comprising first andsecond tonal sub-ranges corresponding to the first and second printabletone levels, respectively, for the first colorant;
 5. The method ofclaim 4, wherein step (b) further comprises the step of creatingbeginning and ending boundary tone values for each of the first andsecond tonal sub-ranges defining first and second tone range spans and afirst transition tone value to be both said ending boundary tone valueof said first tonal sub-range and said beginning boundary tone value ofsaid second tonal sub-range.
 6. The method of claim 5, wherein step (d)further comprises the step of creating beginning and ending boundarytone values for each of the first and second tonal sub-ranges definingfirst and second tone range spans and a first transition tone value tobe both said ending boundary tone value of said first tonal sub-rangeand said beginning boundary tone value of said second tonal sub-range.7. The method of claim 6, further comprising a step (e) of shifting theposition of said first transition tone value of said second set of tonalsub-ranges so that said first tone range span of said second set oftonal sub-ranges is different from said first tone range span of saidfirst set of tonal sub-ranges.
 8. The method of claim 7, furthercomprising a step (f) of producing a modified output tone value for saidfirst and second sub-ranges of said second set of tonal sub-ranges byfirst and second tone modification functions, respectively.
 9. Themethod of claim 8, further comprising a step (g) of producing a singlemulti-bit output value corresponding to the first colorant for eachprintable position on the page by using said modified output tone valueof said first and second tone modification functions as inputs to atleast one half-toning algorithm.
 10. A raster image processor forproducing a screened multi-bit data output file for a digital printingmachine having first and second nozzles that each can print on a page afirst printable tone level, a second printable tone level, and a thirdprintable tone level, from an unscreened raster data file specifying acontinuous tone value for a first colorant for each printable X-Yposition of the page, the raster image processor comprising: a computingdevice; a memory device connected with said computer device; a screeningmodule comprising: a tone sub-range module comprising a first set ofcode configured to create a first set of tonal sub-ranges correspondingto the first nozzle; said first set of tonal sub-ranges comprising firstand second tonal sub-ranges corresponding to the first and secondprintable tone levels, respectively, for the first colorant; each ofsaid first and second tonal sub-ranges comprising beginning and endingboundary tone values defining first and second tone range spans and afirst transition tone value to be the value of both said ending boundarytone value of said first tonal sub-range and said beginning boundarytone value of said second tonal sub-range; said tone sub-range modulefurther comprising a second set of code configured to create a set oftonal sub-ranges corresponding to the first nozzle; said second set oftonal sub-ranges comprising first and second tonal sub-rangescorresponding to the first and second printable tone levels,respectively, for the first colorant; each of said first and secondtonal sub-ranges of said second set of tonal sub-ranges comprisingbeginning and ending boundary tone values defining first and second tonerange spans and a first transition tone value to be the value of bothsaid ending boundary tone value of said first tonal sub-range and saidbeginning boundary tone value of said second tonal sub-range of saidsecond set of tonal sub-ranges; and a shifting module configured toshift the position of said first transition tone value so that saidfirst tone range span of said second set of tonal sub-ranges isdifferent from said first tone range span of said first set of tonalsub-ranges.
 11. The raster image processor of claim 10, furthercomprising a pixel processing module comprising a tone modificationsub-module configured to produce a modified output tone value for saidfirst and second tonal sub-ranges by first and second tone modificationfunctions, respectively; said pixel processing module further comprisesan output sub-module configured to produce a single multi-bit outputvalue corresponding to the first colorant for each printable position onthe page by using said modified output tone values from said first andsecond tone modification functions as inputs to at least one half-toningalgorithm.